Method for operating a round baler and a round baler

ABSTRACT

The present disclosure refers to a method for operating a round baler. The method comprises providing a nonstop baler type machine; controlling a feeding mechanism for feeding of crop into a prechamber and a main bale forming chamber by a control system of the baler; in a feeding operation, feeding the crop through a first feeding channel into the prechamber; and switching the feeding operation by the control system, thereby, stopping feeding the crop into the prechamber and starting feeding the crop through a second feeding channel into a main bale forming chamber of the baler. The control system is configured to switch the feeding operation in response to a binding material parameter reaching a predetermined parameter value, the binding material provided for wrapping a bale formed in the main bale forming chamber. Furthermore, a round baler is disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a 35 U.S.C. 371 National Stage Patent Application ofInternational Application No. PCT/EP2018/070292, filed Jul. 26, 2018,which claims priority to European application 17187076.9, filed Aug. 21,2017, each of which is hereby incorporated by reference in its entirety.

The present disclosure refers to a method for operating a round balerand a round baler.

BACKGROUND

A baling machine, usually existing of the round or rectangular bale typeis used to package crop material into a round or rectangular shape.

A baling machine can be divided up into various areas of components andapparatuses. One of the primary components of the baler is the bindingunit usually commonly used to apply a twine/net or a sheeted typematerial to the bale of product. The binding apparatus can be located onthe baler in various locations depending on the type of machine and itsuse.

Applying binding material to the bale can be a difficult process toachieve high levels of reliability. In particular, problems exist withsheeted materials in that the surface of the material is not of the meshtype and as a result the crop on the bale does not bond with the bindingmaterial as efficient as of the mesh type of binding. As a result, thebinding sheet type material can often fail to follow the circumferenceof the bale and may instead follow a rotating component of the balingmachine.

In general the machines that can apply this type of sheet bindingmaterial, the operator needs to manipulate the intake of crop into themachine as the binding material is being fed into the baling chamber sothe incoming crop can enclose the first parts of the sheet materialwithin layers of crop so the sheet binding material is trapped betweenthe crop layers and as a result can successfully follow around thecircumference of the bale without leaving the baling chamber.

This intake of crop material to enclose the first parts of the bindingmaterial with the crop on the bale is not automated by the machine butinstead is solely carried out by the skill of the operator of themachine. This is a difficult process and can also be very unreliable asthe operator has to judge the quantity of crop entering the machine andalso judge the forward speed correctly of the baling machine. In astandard stop start baler, the driver needs to stop when the balingchamber is full in order to apply the binding material. If the driverstops too early the first part of the binding material will not beenclosed in the bale and the binding material may not follow the balescircumference, if the driver drives forward too far after the balingchamber is full, the first part of the binding material will be enclosedtoo far beneath the bales surface and excess crop will cover the plasticcausing issues at a later stage with the preservation of the cropmaterial and the removal of the binding material. The issues alsoinclude incorrect over lap of the binding material, excess crop betweenthe binding layers allowing air or and moisture to enter the bale and/oraccumulative issues when trying to remove the binding material from thebale.

Another problem with the binding material of the sheeted plastic type isproviding a reliable apparatus to feed the plastic into the chamber, toprovide a stretching of the plastic and then to remove some of thebraking force at the end of the binding cycle to successfully cut thebinding material so the cycle may be successfully started again on thenext bale. Due to the elasticity of the binding material, thebraking/stretch of the plastic sheet material must be removed at the endof the cycle in order to prevent excessive contraction of the plasticbinding material. If there is excessive contraction of the stretchedbinding material, reliable feeding of the material at the start of thenext bale binding cycle may not be possible.

Commonly, a roller is used to provide a stretch on the binding thematerial. Either the braking roller is pushed onto the roll of bindingmaterial and or the binding material is routed around the braking rollerfor stretching the binding material. The binding material may be wrappedaround the braking roller between 100 and 300 degrees of contact withthe braking roller depending on the machine type.

The applying compressive force from the braking roller pushing onto thecircumference of the roll of plastic may be limited because when feedingthe binding material at the start of the binding process, it would notbe possible to pull the binding material from the roll of bindingmaterial due to the high rolling resistance caused by the excessivecompressive forces. As a result of this limited compressive forcebetween the braking roller and the roll of binding material, limitationswill exist when stretching the binding material at the higher stretchpercentages.

The problem presented is, if the force of the braking roller pushingonto the roll of binding material is too great, the binding apparatuswill be unable to draw the binding material from the roll of binding sothe binding material can enter the baling chamber. If the force of thebraking roller pushing on the roll of binding is not sufficient, therelease of the braking rotational force at the end of the binding cyclein order to cut the material, the momentum in the roll of bindingmaterial will cause the roll of material to rotate after the bindingmaterial has been cut and binding cycle has ended. With all of thecurrent binding stretching systems, the stretching roller is always incontact with the binding material either through the binding materialpassing over, between or around the stretching roller or the stretchingroller is pushing on the roll of binding material directly at all times.As a result, if the stretching is excessive or not enough, the bindingmaterial passing through the stretching roller can overrun, pullbackwards or bind to the stretching roller and as a result, the bindingmaterial is not free for the start of the next binding cycle. Thesystems currently existing have disadvantages of needing to be finelytuning the forces to try and overcome the problems.

Document EP 3 132 672 A1 shows a binding system with abraking/stretching roller and a braking force controlled with a motor. Abinding material is in constant contact with the braking/stretchingroller at all stages of the binding cycle. As a result, the system needsto be finely tuned especially at the end of the cycle when cutting thebinding material so the binding material does not overrun causing thebinding material to fully wrap or become lodged on thebraking/stretching roller.

Another example of prior art is document WO 2013/124836 A1. In thisexample a braked/stretch roller is in contact with a binding materialand the binding material also wraps around the roller. If the bindingmaterial overruns at any point of the binding cycle or breaks at anypoint of the binding cycle, the plastic will inevitably become entangledand fully wrapped around the braked/stretch roller. This is a majordisadvantage with these known binding systerns.

SUMMARY

It is an object to provide a method for operating a round baler and around baler with improved operation control.

For solving the problem a method for operating a round baler and a roundbaler are provided.

According to an aspect, a method for operating a round baler isprovided, comprising: providing a nonstop baler type machine;controlling a feeding mechanism for feeding of crop into a prechamberand a main bale forming chamber by a control system of the baler; in afeeding operation, feeding the crop through a first feeding channel intothe prechamber; and switching the feeding operation by the controlsystem, thereby, stopping feeding the crop into the prechamber andstarting feeding the crop through a second feeding channel into a mainbale forming chamber of the baler. The control system is configured toswitch the feeding operation in response to a binding material parameterreaching a predetermined parameter value, the binding material providedfor wrapping a bale formed in the main bale forming chamber.

According to another aspect, a round baler is provided, comprising: aprechamber; a main bale forming chamber; a first feed channel configuredto feed crop into the prechamber; a second feed channel configured tofeed the crop into the main bale forming chamber; and a control system.The control system is configured to switch a feeding operation forfeeding crop into the prechamber and, after stopping feeding of the cropinto the prechamber, starting feeding the crop into a main bale formingchamber; and to apply the switching in response to a binding materialparameter reaching a predetermined parameter value, the binding materialprovided for wrapping a bale formed in the main bale forming chamber.

The round baler may be a nonstop baler type machine.

The control system may be configured to switch the feeding operationwhen the binding material reaches a predetermined location between 0 and360 degrees on the circumference of the bale formed in the main baleforming chamber.

The control system may be configured to switch the feeding operationwhen the binding material reaches a predetermined value corresponding toa point in the circumference of the main bale forming chamber.

The control system may be configured to switch the feeding operation asthe binding material is wrapping the bale formed in the main baleforming chamber.

The control system may be configured to switch the feeding operationwhen the binding material is wrapping the bale formed in the main baleforming chamber.

The control system may be configured to determine the length of thebinding material wrapped around the bale, and to switch the feedingoperation when the length of the binding material wrapped around thebale reaches a specific length.

The method may further comprise: stopping the crop from entering themain bale forming chamber at a predetermined value of a binding cyclefor wrapping the bale by the binding material; and covering the bindingmaterial by a volume of the crop.

The binding material may be provided as at least one of a plasticbinding material and a sheet material. The binding material may providean oxygen barrier when wrapped around the bale.

The method may further comprise switching the feeding operation byswitching a moveable plate in a crop channel.

With respect to the round baler, the aspects described above withrespect to the method for operating may apply mutatis mutandis.

In a further example, a round baler for forming a bale from a cropproduct is provided. The round baler comprises a prechamber providedwith a first feeding channel to feed crop into the prechamber and a mainbale forming chamber provided with a second feeding channel to feed cropinto the main bale forming chamber. The baler further comprises afeeding mechanism which is configured to feed crop to the prechamberand/or to the main bale forming chamber. Also, the baler comprises acontrol system for controlling the feeding mechanism, wherein thecontrol system is configured to stop feeding crop to the prechamber andstart feeding crop to the main bale forming chamber and/or stop feedingcrop to the main bale forming chamber and start feeding crop to theprechamber. The control system is configured to switch the feedingoperation when the binding material has a specific parameter, e.g. aspecific length.

In operation, the main bale forming chamber may be filled to form a baleof crop material. The binding cycle may begin prior to the main baleforming chamber reaching a full state, as the binding material isapplied onto the bale of crop material; incoming crop encloses astarting end of the binding material into the bale of crop material. Ata predefined point, e.g. when the binding material has a specific lengthand/or the binding material reaches a predefined location on the balescircumference, the control system may switch the crop flow from the mainbale forming chamber to the prechamber.

In particular, the process of enclosing a first part of the bindingmaterial at a predetermined location on the circumference of the balemay be automated. A minimum quantity of crop needed to enclose the firstpart of the binding material in the bale's circumference can be definedas part of the automation of the machine's crop flow and baling systems.For example, the length of the binding material wrapped around the balecan be determined. A specific length of the binding material may lead tothe conclusion that the binding material has reached the predeterminedlocation so that it is ensured that some crop is arranged on the bindingmaterial.

The control system may be configured to change a direction of the flowof the crop material feeding into the main bale forming chamber into theprechamber. The control system may be programmed to alter the directionof flow of the crop material when the binding material is any locationfrom 0 to 360 degrees on the bale's circumference in the main baleforming chamber.

The linear length of the binding material may be measured as it wrapsthe bale of crop in the main bale forming chamber. When the bindingmaterial reaches a certain predetermined set value which corresponds toa point in the baling chamber's circumference, the control system mayalter the direction of the crop from one chamber to the other chamber.As a result, the crop flow is automatically stopped from entering themain bale forming chamber at a predetermined value in the binding cycleand the binding material can be covered by a specific volume of incomingcrop which may be automatically controlled by the control system,therefore removing the need for an action by the operator of themachine.

A predetermined value selected in the control system, which may belinearly linked to a location in the bale chambers circumference, maynot be affected by a rotational speed of the main bale forming chamberand/or the prechamber. The rotational speed of the chambers may bedirectly related to a linear speed at which the binding material entersthe main bale forming chamber and follows the bales circumference. As aresult, the predetermined point for switching the crop from one of thechambers to the other chamber will remain the same.

A system to obtain signalled information from the machine may beprovided, a calculating process to translate information throughformulation and a means for the formulated information to influence thedevices on the baling machine to control the crop flow into either ofthe baler's chambers may be provided.

Signalled information may be obtained and recorded from the chambers'rotational speed. In addition or alternatively, signalled informationmay be obtained from the main bale forming chamber concerning thepressures within the main bale forming chamber of compressing the cropmaterial into a bale and signalled information may be recordedconcerning the bale size within the main bale forming chamber.

A calculating process may be applied to provide simultaneous calculationfrom the signals received from the chambers. When a predetermined valueis reached for the bale pressure and/or the bale size, the binding unitmay be activated by the control system. The binding material is then fedinto the main bale forming chamber. As the binding material is fed intothe main bale forming chamber, further signalled information may berelayed back to the control system. The signalled information may thenbe processed and a formulation process may take place to calculate thelength of the binding material entering the main bale forming chamber.When a predetermined value is reached, the control system may send asignal to change the crop flow direction from one chamber to the otherchamber.

The switching of the crop flow from one chamber to the other chamberwhen the binding material has reached a predetermined set value may beautomated by the baler's systems.

The crop may be switched from the main bale forming chamber to theprechamber with a moveable plate in a crop channel. Signalledinformation may be related back to a processor of the control system,and the processor may engage in a process to translate the signalledinformation into positional information to relay the position of theplate in the crop channel. The signalled information may later berelayed to the processor concerning the bale size and/or the density ofthe bale. At a predetermined value for the bale density and/or the balesize, the processor may relay information to start the binding process.Signalled information may be relayed back from the binding unit'sfeeding roller to determine the length of binding material entering themain bale forming chamber. The signalled information received by thebaler's processor may be calculated using formulation resulting in alinear length of the binding material entering the main bale formingchamber being determined. When a preselected length of binding materialhas entered the main bale forming chamber, the processor may signal tothe control system to move the crop to the prechamber.

The control system may start the binding of the bale prior to the balereaching its 100% (full) size and density, resulting in the bindingmaterial reaching a designated radial position on the circumference ofthe bale as the bale reaches the full 100% in size and density aspreselected parameters by the control system followed by the process ofthe crop switching paths to the prebale forming chamber.

The control system may automatically adjust (correction process by thecontrol system) the starting bale size and density (<100%) of the balecontrol the starting of the binding and therefore at 100% bale size anddensity, the binding material is seated on a preselected radial point onthe bales circumference as such point the crop passage is altered fromthe main bale forming chamber into the prebale forming chamber.

The starting of the binding at a starting bale size and density (<100%)can be altered/corrected automatically by the control system dependingon the result of the previous bale, the control system automaticallycalculates the finished size and density of the bale post binding cycleresulting in a corrective calculation to start the next binding cycle ata later % bale size and or density or at an earlier % bale size anddensity depending on the final bale size and density calculation of thebale post binding cycle

The control system may automatically calculate and adjust the startingbale size and density for the binding to start resulting in a final balesize that is consistent with the initial parameters inputted into thecontrol to have a final bale of product that is comparable in size anddensity to the actual parameters inputted or preset on the balerscontrol system.

It is another aim to

-   a) provide a binding system with a stretching mechanism that does    not need to be finely tuned,-   b) remove the possibility of the binding material wrapping or    becoming entangled on the stretching/braking roller at any stage    during the application of binding material to a bale of crop during    the binding cycle, and/or-   c) provide the possibility to apply a compressive force from the    braking apparatus onto the roll of binding during the stretching of    the binding material.

It is also an aim to improve on the apparatus and process required tofeed the binding material into the chamber reliably. This may beachieved by removing all contact of the stretching/braking roller withthe binding material at the start of the binding cycle so all frictionalforces are removed when feeding the binding material from the roll ofbinding material into the baling chamber to an accurate reliable leveland/or by releasing the stretching/brake at the end of the binding cyclefor a reliable ending to the cycle so the next binding cycle startsagain reliably.

With regard to sheeted type binding materials, the invention aims toincrease the level of reliability when applying a binding material to around or rectangular bale.

A binding unit is provided. The binding unit may comprise a feedingmeans which is configured to feed a binding material into a balingchamber; a stretching means which is configured to stretch the bindingmaterial when wrapping the bale of material within the baling chamber;and/or a cutting means which is configured to cut the binding materialwhen the preselected length of binding material has covered the bale.

The stretching means may comprise a stretch roller with an externalbraking force applied to the stretch roller in order to provide abraking effect for the binding material while in contact with thebinding material. A non-stretching means may comprise the stretchingmeans configured to automatically remove all external braking forcesapplied to the stretch roller while in the same configuration removingall physical contact with the binding material.

Also, a stretching apparatus for the binding material may comprisemultiple of modes within one stretching means apparatus. In “feeding ofthe binding material into the chamber” mode, the stretching apparatusmay remove contact with the binding material. In “binding materialinitial stretch” mode, the stretching apparatus may move the stretchroller into a free rolling contact with the binding material roll. In a“2nd stretch” mode, the stretching apparatus may apply a predeterminedforce to the stretch roller which applies a stretch to the bindingmaterial. In “initial end of cycle” mode, the braking force from thestretch roller may be removed and the stretch roller may remain in freerolling contact. In “out of contact” mode with the binding materialroll, a “2nd end of cycle” mode may allow the cutting of the bindingmaterial with the application of a braking force on the stretch rollersimultaneously as the cutting action is taking place.

The binding unit may be provided with a stretching means and anon-stretching means controllable by an actuating means. The brakingapparatus may comprise a means of controlling the braking forces tostretch the binding material and/or may comprise a means of controllingthe location of the stretching roller means in relation to the locationof the binding material from physical contact with the binding materialin a general forward and reverse movement.

The stretching means apparatus actuator may comprise a dual function. Asingle actuating means may remove the stretching means from contact withthe binding material and alternatively may position the stretch rollercombined with the braking apparatus of the stretch roller onto thebinding material to achieve a preselected stretch ratio.

Also, a binding material stretching means may be provided. The bindingmaterial stretching means may comprise a stretching apparatus comprisingstretching roller and braking means, for the stretch roller. The stretchroller may comprise dual braking means. A secondary braking means maycomprise an independent braking force on the stretch roller provided bya means independent of the braking apparatus of the stretch roller ontothe binding material. A primary stretching roller braking means may beresponsible for the primary braking forces on the binding materialsupplemented by the secondary braking means independent of the primarybraking means dually combining to provide the preselected bindingmaterial stretch ratio.

A binding material stretching means may be provided which may comprise astretching apparatus comprising stretching roller and braking means, forthe stretch roller. The stretching apparatus may comprise a plurality ofstretching means independently applying braking forces to the stretchroller. Primary forces may be applied through an actuator applying afriction means on the stretch roller to brake the stretch roller. Asecondary breaking means may apply a secondary force to the stretchroller through the stretch roller supporting frame by an external forceindependent of the friction means providing the primary braking means onthe binding material. The secondary force may create additionalfrictional contact between the inner tube of the roll of bindingmaterial and a center supporting axle while the primary stretching meansmay create a braking to the rotational speed of the stretch roller.

A binding unit may be provided. The binding unit may comprise multipleindependent braking forces comprising primarily of primary and secondaryforces each of which may contribute to the surface contact pressureapplied between the binding material stretch roller and the roll ofbinding material. The primary stretching roller braking means maycomprise a friction means to provide a braking force on the stretchroller, the same braking force may provide a surface contact pressure onthe roll of binding material preventing slippage, while the secondaryindependent braking force also may provide a force complementing theprimary forces for surface contact pressure on the roll of bindingmaterial preventing slippage of the stretch rollers surface against thebinding materials surface.

A binding unit with a stretching apparatus in which the stretch rollermay be removed from surface contact with any part of the bindingmaterials roll or layered part of the material from dispatching from theroll through to engagement on the bale of materials circumference may beprovided.

The binding unit may comprise a stretching apparatus comprising of abraked roller with braking forces causing a reversing of the directionof the braked roller. The braking forces may be applied to the externalface of the stretch roller through an actuator means applying a force tothe frictional means which then may apply a force to the stretch rollersouter surface resulting in a slowing down of the circumference speed ofthe stretch rollers surface causing the binding material dispatchingfrom the binding material roll to slow down resulting in speeddifference between the baling chamber and the dispatched bindingmaterial speeds.

The binding unit may comprise a stretching apparatus comprising anactuator. The actuator may provide multiple actions within the bindingunit, may remove the stretch roller from contact with the bindingmaterial for feeding of the binding material at the start of the cycle,may engage the braking means, may apply the preselected pressure on thebraking means, e.g. by the extension of springs, may regulate thebraking means for the end of the binding cycles cutting phase and mayremove the stretch roller to an area external of that of the roll ofbinding materials circumference diameter to recharge the binding unitwith a full roll of binding material.

It may be possible to apply large compressive forces between the brakingroller and the roll of binding material which forces may not be limitedby the force necessary to pull the binding material from the roll ofbinding material at the start of the binding process. When feeding thebinding material, the large compressive forces may be removed completelyby the functionality of the binding unit, for example by removing thestretch roller from contact with the binding material.

The binding unit may be provided with a stretching apparatus thatprovides a rotational/lateral movement of the braking means, thestretching apparatus moving the braking means in a positive workingdirection to apply a braking force onto the roll of binding material andtherefore onto the sheeted material dispensing from the roll of bindingmaterial. Deactivation of the stretch of the binding material may beprovided by the stretching apparatus and braking means moving in adirection opposite the working direction, increasing the distancebetween the circumferences of the braking roller of the braking meansand the circumference of the roll of binding material.

The binding unit may comprise a stretching apparatus with a brakingmeans. For braking, the braking means may move in a positive directiontowards the binding material roll, resulting in the distance between thecircumference of the braking means roller and the circumference of theroll of binding material decreasing until reaching a value of zero.Further movement in the positive direction may result in compressiveforces of the braking means against the binding material roll.

The binding unit may comprise a stretching apparatus with a brakingmeans. When a working mode of the binding unit is activated, the brakingmeans may move in a positive direction until the braking means brakingroller's circumference makes contact with the circumference of thebinding material. After physical contact has been made, the brakingmeans may apply a compressive force to the roll of binding material.

The binding unit comprising the stretching apparatus and the roll ofbinding material may be represented by a Venn diagram with two sets. Setone (denoted as A) may represent the braking apparatus and set two(denoted as B) may represent the roll of binding material. Theintersection of the sets A and B may represent the braking apparatusbeing in physical contact with the circumference of the roll of bindingmaterial. The union of the sets A and B may represent the binding unitcomprising the stretching apparatus and the roll of binding material.

The binding unit may comprise a stretching apparatus. The stretchingapparatus may comprise one or more braking or stretching rollers. Abraking force on the circumference of the braking/stretching roller maytranslate into a compressive force on the contact surface area betweenthe circumference of the braking roller and the circumference of theroll of binding material. An increase in the force on the brake may leadto an increase in the compressive force between the braking roller andthe binding material roll. There may be a linear relationship betweenthe increase in braking resistance on the braking roller and theincrease of the compression forces between the braking roller and theroll of binding material. The compression force between the brakingroller and the roll of binding material may increase the surfacefriction between the braking roller and the circumference of the roll ofbinding material. The increase in surface friction may decrease theprobability of slippage occurring between the surface of the brakingroller and the surface of the roll of binding material during thestretching of the binding material.

The method may comprise providing a compressive force against at leastone of a surface of the first stretching roller and a surface of thesecond stretching roller. The compressive force may be applied bypushing some braking element against the rollers surface, thereby,causing friction between the rollers surface and the braking element.

By the compressive force against the surface of at least one of thestretching (braking) rollers a second braking force may be provided, thesecond braking force being provided in addition to the compressive force(first braking force) against the binding material. The second brakingforce is applied to the rotation of at least one of the first and secondstretching (braking) rollers.

In an example, the first compressive force (first braking force) may beapplied to the binding material by the first (stretching) brakingroller. A second compressive force (second braking force) may be appliedto the rotation of at least one of the first and second braking rollerssurface which results in the stretching of the binding material. Thefirst compressive force may be different from secondary braking force.Thus, in this example, the stretching of the binding material can beadjusted by adjusting at least one of the first compressive force(ap-plied by the stretching roller(s) against the binding material) andthe second compressive force (against the surface of the stretchingroller(s)). A primary and a secondary braking mechanism are provided.

The sum of the primary braking force(s) (i.e. force applied to thebinding material by the stretching roller) and the secondary brakingforce(s) (i.e. force applied to the rotation of the braking rollerssurface) provide in totality the braking for the binding apparatus forstretching the binding material.

In the first mode of operation for the braking device or apparatus thereis physical contact between the braking (stretching) roller(s) and thebinding material. The compressive force of the braking roller(s) appliedcompresses on the binding roll. Such force may be the result of aprimary and a secondary braking apparatus/mechanism. The secondarybraking apparatus which applies a positive braking force to the rotatingstretching (braking) roller(s) being in contact with the bindingmaterial which adds to the overall braking force. The primary brakingmechanism applies a frictional force to the braking roller to reduce thebraking rollers rotational speed to provide the stretching rate to thebinding material.

BRIEF DESCRIPTION OF THE DRAWINGS

Following, further embodiments are described by referring to figures. Inthe figures show:

FIG. 1 a schematic representation of crop flow to the main bale formingchamber, the crop flow entering the chamber encloses the bindingmaterial between the outer layer of crop on the bale and the innermaterial on the bale;

FIG. 2 a schematic representation of the switching of the crop flow tothe baler's prechamber at a predetermined point on the balescircumference of the binding material;

FIG. 3 a schematic representation of a binding apparatus, wherein thebinding apparatus is provided with a braking mechanism, within thebraking mechanism the stretch roller locates in the parked/binding rollrecharge position;

FIG. 4 a schematic representation of a binding apparatus, wherein thebraking mechanism is shown, within the braking mechanism the stretchroller locates in the binding feed position, located away from thebinding material;

FIG. 5 a schematic representation of the binding apparatus, wherein thebraking mechanism is shown, within the braking mechanism the stretchroller locates in the stretching position, the stretching position, thestretch roller applying a braking force on the binding material roll;and

FIG. 6 a schematic representation of the binding apparatus, wherein thebraking mechanism is shown, within the braking mechanism the stretchroller locates in the binding material roll change recharge position.

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a schematic representation of a baling machine 10 of thenonstop type. The baling machine 10 is provided with a prechamber 20 inwhich a preformed bale is prepared in the process of forming a bale fromcrop 41. There is a feeding channel 21 configured to feed the crop 41picked up by a crop pickup mechanism 42 to the prechamber 20.

There is a second feeding channel 45 for feeding or guiding the crop 41into a main baling forming chamber 60. In the main bale forming chamber60 a full bale of crop material is prepared.

A crop cutting device 43 is provided. A crop switching plate 44 can bepivoted on the rear side of the crop cutting device 43 for guiding thecrop 41 to at least one of the prechamber 20 and the main bale formingchamber 60.

The feeding of the crop 41 is conducted by a feeding mechanism 47.

While according to FIG. 1 the crop 41 is fed to the main bale formingchamber 60, the crop 41 is fed to the prechamber 20 according to FIG. 2when the crop switching plate 44 is in a different position compared toFIG. 1 .

A binding apparatus 31 is provided for the baling machine 10. Thebinding apparatus 31 is provided with a roll 32 of binding material. Abinding material pathway 33 is provided. A tail end 34 of the bindingmaterial is on the circumference of the bale 11.

Further, a feeding roller 35 is provided for the binding apparatus 31.

Referring to FIGS. 3 to 7 , further aspects are described, specificallywith respect to the binding apparatus 31 provided in a binding unit 100.

In FIGS. 3 to 6 bale chamber rollers 102 are depicted applied forforming the bale 11.

A braking apparatus structure 111 is provided.

There are binding material guide rollers 112.

The binding unit 100 is provided with a frame 113. With respect to thebinding unit 100, a binding apparatus grouping mechanism 114 and abinding material cutting mechanism 115 are provided.

A part 116 of the binding material 117 is entering the main bale formingchamber 60 between one of the bale chamber rollers 102 and thecircumference of the bale 11.

The binding material is provided by a roll of binding material 117. Thebinding material is moved along a path 118 when leaving the roll ofbinding material 117.

A stretch roller 119 is provided. The stretch roller 119 is configuredto contact the binding material 117 with different forces or no forcesto allow the binding material 117 to move freely, to stretch the bindingmaterial 117 with controlled tension as the binding material is wrappingthe bale, and to apply braking forces to the binding material 117.

A secondary force depicted by reference numeral 120 is applied to thestretch roller 119.

There is a braking mechanism 121 of the braking apparatus structure 111for providing a braking function.

A primary force depicted by reference numeral 122 is applied to thestretch roller 119.

There is a primary force monitoring device 123.

A connecting rod 124 is connecting an actuator 110 for braking in thebrake mechanism.

Further, a binding material feeding roller 125 is provided.

FIG. 3 shows a schematic representation of a binding apparatus 31,wherein the binding apparatus 31 is provided with a braking mechanism,within the braking mechanism the stretch roller locates in theparked/binding roll recharge position. In this state, the bindingapparatus 31 is in a switch over state, the braking mechanism 121 islifted into a home position so the binding material roll can berecharged when the binding material 117 goes empty.

FIG. 4 shows a schematic representation of the binding apparatus 31,wherein the braking mechanism 121 is shown. Within the braking mechanism121, the stretch roller 119 is places in the binding feed position awayfrom and not contacting the binding material 117. The binding apparatus31 is now engaged in the working mode, the roll of binding material 117is in position and the braking mechanism 121 lifts the stretch roller119 from the binding materials surface so the binding material 117 canbe pulled from the roll and fed into the baling chamber 60. The bindingmaterial follows a path 118 from the circumference of the roll ofbinding material 117 over the guiding rollers 112, between the plasticgrouping sys-tem 114, through the binding systems feeding rollers 125and binding material cutting mechanism 115 and in-to the baling chamber60.

FIG. 5 shows a schematic representation of the binding apparatusdepicting the braking mechanism 121. Within the braking mechanism, thestretch roller is placed in a stretching position in which the stretchroller 119 applies a braking force on the binding material roll. Thestretch roller 119 is pressed onto the circumference of the roll ofbinding material 117 by the actuator moving the connecting rods 124which increases the primary force 122 via tension springs in theembodiment of FIG. 5 . Primary force 122 is increased at the brakingroller braking mechanism which in turn increases the friction of thebraking mechanism onto the stretch roller 119, therefore slowing downthe circumference rotation speed of the stretch roller 119 and slowingdown the circumference rotation speed of the roll of binding material117. The arrangement in this embodiment provides a speed differencebetween the roll of binding material 117 and the baling chamber thusproviding stretching of the binding material. Secondary force applied tothe braking roller 120 applies a force to the braking apparatusstructure 111 which applies a secondary force to the stretch roller 119and therefore to the roll of binding material 117.

The primary force monitoring device detects the position of the Primaryforce applied to braking roller mechanism in which its parameters can beadjusted to provide various levels of stretch to binding material 117.When the roll of binding material 117 is in position and the brakingmechanism 121 is lifted from the stretch roller 119, the bindingmaterial 117 can be cut by the binding material cutting mechanism 115.

FIG. 6 shows a schematic representation of the binding apparatus 31,wherein the braking mechanism is shown. The primary braking force 122 isremoved from the stretch roller 119 and the secondary braking force 120is removed by the lifting of the stretch roller 119 from being incontact with the binding material 117.

The features disclosed in this specification, the figures and/or theclaims may be material for the realization of various embodiments, takenin isolation or in various combinations thereof.

REFERENCE LIST

-   10 Baling machine of the nonstop type-   11 Bale-   20 Prechamber-   21 Feeding channel entering the prechamber-   31 Binding apparatus-   32 Roll of binding material-   33 Binding material and binding material pathway-   34 Tail end of the binding material on the bale's circumference-   35 Feeding roller and binding material cutting mechanism-   42 Crop pickup mechanism-   43 Crop cutting device-   44 Crop switching plate pivoting on the rear side of the crop    cutting device, in this position guides crop to the main bale    forming chamber-   45 Crop channel for guiding crop into the main baling chamber-   46 Crop switching plate pivoting on the rear side of the crop    cutting device, in this position guides crop to the prechamber-   47 Feeding mechanism-   60 Main bale forming chamber with a full bale of material-   100 Binding unit-   102 Bale chamber rollers-   103 Bale of material-   111 Braking apparatus structure-   112 Binding material guide rollers-   113 Frame of binding unit-   114 Binding apparatus grouping mechanism-   115 Binding material cutting mechanism-   116 Binding material entering bale chamber between roller and bale    circumference-   117 Roll of binding material-   118 Path of binding material leaving from the roll of binding    material-   119 Stretch roller (Stretching/braking roller)-   120 Secondary force applied to the braking roller-   121 Braking roller braking mechanism-   122 Primary force applied to braking roller mechanism-   123 Primary force monitoring device-   124 Connecting rod, connecting actuator to braking roller brake    mechanism-   125 Binding material feeding roller

The invention claimed is:
 1. A method for operating a round baler,comprising providing a nonstop baler type machine; controlling a feedingmechanism for feeding of crop into a prechamber and a main bale formingchamber by a control system of the baler; in a feeding operation,feeding the crop through a first feeding channel into the prechamber;switching the feeding operation by the control system, thereby, stoppingfeeding of the crop into the prechamber and started feeding of the cropthrough a second feeding channel into a main bale forming chamber of thebaler; Sensing or calculating, by the control system, a bale size as abale is formed in the main bale forming chamber of the baler;activating, by the control system, a binding unit to feed a bindingmaterial into the main bale forming chamber to attach to a balecircumference when the bale size is determined to reach a bale size thatis less than a full bale size; sensing or calculating, by the controlsystem, a binding material parameter indicative of a bale circumferenceas crop continues to enter the main bale forming chamber; stretching thebinding material using a stretch roller as the binding material is fedinto the main bale forming chamber; applying a braking force on thestretch roller to increase surface tension between the stretch rollerand the binding material; releasing the braking force on the stretchroller as the binding material parameter indicates the balecircumference is approaching the full bale size; and switching thefeeding operation to feed the crop from the main bale forming chamber tothe prechamber in response to the binding material parameter reachingthe predetermined value indicative of a substantially full bale size. 2.The method according to claim 1, wherein the step of switching thefeeding operation includes switching the feeding operation to feed cropinto the prechamber when the binding material parameter reaches thepredetermined value indicative of a predetermined location between 0 and360 degrees on the circumference of the bale formed in the main baleforming chamber.
 3. The method according to claim 1, wherein the step ofswitching the feeding operation includes switching the feeding operationto feed crop into the prechamber when the binding material reaches apredetermined value corresponding to a point in the circumference of themain bale forming chamber.
 4. The method according to claim 1, whereinthe step of switching the feeding operation as the binding material iswrapping the bale formed in the main bale forming chamber.
 5. The methodaccording to claim 1, wherein the control system is configured to: thestep of sensing or calculating the binding material parameter includesdetermining the length of the binding material wrapped around the bale,and the step of switching the feeding operation is performed when thelength of the binding material wrapped around the bale reaches aspecific length.
 6. The method according to claim 1, further comprisingstopping the crop from entering the main bale forming chamber at apredetermined value of a binding cycle for wrapping the bale by thebinding material; and covering the binding material by a volume of thecrop.
 7. The method according to claim 1, wherein the binding materialprovided as at least one of a plastic binding material and a sheetmaterial.
 8. The method according to claim 1, further comprisingswitching the feeding operation by switching a moveable plate in a cropchannel.
 9. A round baler, comprising a prechamber; a main bale formingchamber; a pressure sensing mechanism in the main bale forming chamberconfigured to sense bale pressure increases in the main bale chamber; afirst feed channel configured to feed crop into the prechamber; a secondfeed channel configured to feed the crop into the main bale formingchamber; a binding unit comprising a binding material roll, a brakingmechanism, a stretch roller, a binding material length monitor, and atleast one binding material guide roller, the binding unit configured torelease a binding material into the main bale forming chamber; and acontrol system configured to; sense a pressure in the main bale formingchamber and calculate a bale size as a bale is formed in the main baleforming chamber of the baler; activate the binding unit to feed thebinding material into the main bale forming chamber to attach to a balecircumference when the bale size is determined to reach a bale size thatis less than a full bale size; sense a length of the binding material,where the length of the binding material is indicative of a balecircumference as crop continues to enter the main bale forming chamber;stretch the binding material using the stretch roller as the bindingmaterial is fed into the main bale forming chamber; apply a brakingforce on the stretch roller to increase surface tension between thestretch roller and the binding material; release the braking force onthe stretch roller as the binding material parameter indicates the balecircumference is approaching the full bale size; and switch the feedingoperation to feed the crop from the main bale forming chamber to theprechamber in response to the binding material parameter reaching thepredetermined value indicative of a substantially full bale size.